Semiconductor package with electromagnetic interference shielding

ABSTRACT

A semiconductor package includes a multilayer package substrate including a first layer including a first dielectric and first metal layer including a first metal trace and a second layer including a second dielectric layer. An integrated circuit (IC) die includes bond pads, with a bottom side of the IC die attached to the first metal trace. Metal pillars are through the second dielectric layer connecting to the first metal trace. A third layer on the second layer includes a third dielectric layer on the second layer extending to a bottom side of the semiconductor package, and a second metal layer including second metal traces including inner second metal traces connected to the bond pads and outer second metal traces over the metal pillars, and filled vias providing externally accessible contact pads that connect the second metal traces to a bottom side of the semiconductor package.

FIELD

This Disclosure relates to electromagnetic shielding for semiconductor packages that include at least one integrated circuit (IC).

BACKGROUND

A challenge faced by electronic designers when designing a semiconductor package that comprises at least one IC which is a precision and/or sensitive IC, or includes precision and/or sensitive components, is electromagnetic interference (EMI) from neighboring electronic components. The precision and/or sensitive components can comprise a power metal oxide semiconductor field effect transistor (power MOSFET), a controller/driver, and analog-to-digital converter (ADC), digital circuitry, control and compensation circuitry, a digital-to-analog converter (DAC), or protection and diagnostic circuitry. The neighboring electronic components causing the EMI can comprise an IC or a discrete device such as an inductor. Because most electronic components during their operation emit at least some EMI, having precision and/or sensitive ICs in proximity to an EMI emitting electronic component(s) can cause the performance of the precision or sensitive IC to suffer.

SUMMARY

This Summary is provided to introduce a brief selection of disclosed concepts in a simplified form that are further described below in the Detailed Description including the drawings provided. This Summary is not intended to limit the claimed subject matter's scope.

Disclosed aspects recognize precision and/or sensitive ICs can have their performance affected by EMI caused by generally any active circuit, and also by some passive devices such as inductors, when located in proximity to the IC. One specific example of an IC sensitive to EMI comprises an audio power amplifier IC, where the audio qualities, such as frequency response, gain, noise, and distortion can degrade in the presence of EMI. Examples of precision ICs that can experience degraded precision in the presence of EMI includes ADCs and DACs. Such precision and/or sensitive ICs, such as in the case of an automotive application, will generally be assembled on the same printed circuit board (PCB) along with other devices which may be EMI emitting.

For example, when a sensitive IC die is packaged in a traditional powerpad package (PWP) that includes gullwing leads, it is difficult to shield EMI emitted from neighboring EMI emitting devices from reaching the sensitive circuitry due to limited PWP design flexibility. Even if some EMI shielding is achieved by the PWP package, the relatively high inductance of gullwing leads with the wirebonds to the bond pads of the IC can significantly increase the ringing, and as a result reduces the EMI shielding effect provided by the PWP package.

Disclosed aspects utilize a multilevel package substrate sometimes referred to as a routable leadframe (RLF), to provide an EMI shielded semiconductor package so that the precision or sensitive IC to EMI can be fully embedded in the package substrate, including being shielded from EMI by metal layer(s) which will generally be grounded in their application (e.g., grounded to a ground terminal on a common PCB). Disclosed package substrates also provide reduced parasitics as compared to conventional semiconductor packages having bond wires including reduced inductance due to the absence of any bond wires.

In a typical application where a disclosed package substrate having a precision or sensitive IC die referred to herein as it being an EMI shielded semiconductor package is attached to pads of a PCB, the EMI shield comprises a top EMI shield comprising a first layer metal and a bottom EMI shield comprising another metal layer. The top and bottom EMI shields are connected together by metal pillars which are positioned beyond the area of the precision or sensitive IC die. The respective EMI shields together with the metal pillars positioned beyond the area of the IC that can define an area beyond the area of the IC referred to herein as a ring around the IC., where the EMI shields together with the metal pillars collectively resemble a Faraday cage for the IC die.

The top EMI shield generally has an area greater than the area of the IC die, and is aligned to be over a full area of the IC. Metal pillars, such as comprising copper, are recognized to provide a low resistance vertical connection from the top metal layer of the package substrate to the bottom EMI shield, which can be provided by a PCB that the package substrate is mounted on. Alternatively, or in addition to a bottom EMI shield provided by the PCB, the inner metal traces of the package substrate can cover at least 50% of the area of the IC die to itself provide a bottom EMI shield.

Disclosed aspects include a semiconductor package comprising a multilayer package substrate including a first layer including a first dielectric layer and a first metal layer including at least a first metal trace and a second layer that includes a second dielectric layer. An IC die includes a semiconductor surface including circuitry, with nodes of the circuitry connected to bond pads. Metal pillars are through the second dielectric layer connecting to the first metal trace. A third layer on the second layer includes a third dielectric layer extending to a bottom side of the semiconductor package, a second metal layer including a plurality of second metal traces comprising inner second metal traces connected to the bond pads and outer second metal traces over the metal pillars, as well as filled vias through the third dielectric layer providing externally accessible contact pads that connect the second metal traces to a bottom side of the semiconductor package.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, wherein:

FIG. 1A-G are successive cross-section views of an in-process EMI shielded semiconductor package comprising a precision or sensitive IC embedded within a multilayer package substrate corresponding to results following steps in an example method for forming an EMI shielded semiconductor package, according to an example aspect. FIG. 1A shows in-process results after forming a first layer on a carrier comprising a first metal trace that is embedded in a first dielectric layer. FIG. 1B shows in-process results after attaching an IC die including circuitry connected to bond pads with its top side up using a die attach material over the first trace. FIG. 1C shows in-process results after forming metal pillars on the first metal trace lateral to the IC die. FIG. 1D shows in-process results after forming a second dielectric layer, and then generally a grinding process to expose a top surface of the metal pillars. FIG. 1E shows in-process results after generally a drilling process through the second dielectric layer over the bond pads to reach the bond pads.

FIG. 1F shows in-process results after forming a third layer on the second layer including a third dielectric layer extending to a bottom side of the semiconductor package, and a second metal layer including a plurality of second metal traces comprising inner second metal traces over the area of the IC die, and outer second metal traces positioned beyond the area of the IC die, and forming filled vias. The filled vias provide externally accessible contact pads that connect the second metal traces to a bottom side of the semiconductor package. FIG. 1G shows in-process results after removing the carrier and flipping the semiconductor package, and then generally a sawing process in the typical case of a panel of EMI shielded semiconductor packages to provide a plurality of singulated EMI shielded packages.

FIG. 2 is a top view corresponding to the structure shown in FIG. 1C which as described above shows in-process results after forming metal pillars on the first trace lateral to the IC die, according to an example aspect.

FIG. 3A and FIG. 3B show a top perspective view and a cross-sectional view, respectively, of a semiconductor package assembly comprising disclosed EMI shielded semiconductor package comprising an IC embedded within a package substrate mounted on pads on a top of a PCB that provides a bottom metal shield for the IC, according to an example aspect. In FIG. 3B, the PCB is also shown with its dielectric having embedded filled vias connected to metal pads.

DETAILED DESCRIPTION

Example aspects are described with reference to the drawings, wherein like reference numerals are used to designate similar or equivalent elements. Illustrated ordering of acts or events should not be considered as limiting, as some acts or events may occur in different order and/or concurrently with other acts or events. Furthermore, some illustrated acts or events may not be required to implement a methodology in accordance with this Disclosure.

Also, the terms “connected to” or “connected with” (and the like) as used herein without further qualification are intended to describe either an indirect or direct electrical connection. Thus, if a first device “connects” to a second device, that connection can be through a direct electrical connection where there are only parasitics in the pathway, or through an indirect electrical connection via intervening items including other devices and connections. For indirect connecting, the intervening item generally does not modify the information of a signal but may adjust its current level, voltage level, and/or power level.

Several terms used herein will now be defined. A multilayer package substrate as used herein is a particular package substrate arrangement that comprises a plurality (at least two) of stacked layers where each layer is pre-configured with metal plating such as copper plating or interconnects to provide electrical connections in the package. Such a package substrate is generally built by forming a dielectric layer such as a mold compound (generally comprising an epoxy material) or other dielectric organic compound(s) around a leadframe substrate comprising a metal material between a patterned top metal layer and a patterned metal bottom layer. Such package substrates can comprise single-die or multi-die configurations, both lateral and vertically stacked, enabling low-profile and fine-pitch packages, which enable different stackups, materials, and manufacturing processes that have recognized benefits when applied to disclosed aspects.

An IC die as used herein comprises a substrate having at least a semiconductor surface (generally an all-semiconductor substrate, such as comprising silicon having an optional epitaxial layer thereon), where there were circuit elements (including transistors, and generally diodes, resistors, capacitors, etc.) formed in the semiconductor surface that are configured together for generally realizing at least one circuit function. Various nodes of the circuitry are connected to bond pads on the top side of the IC, where the bond pads generally comprise the top layer metal for the IC. The IC can comprise a power device such as an amplifier or a power regulator.

FIGS. 1A-G are successive cross-section views of an in-process EMI shielded semiconductor package comprising a precision or sensitive IC embedded within a multilayer package substrate corresponding to results following steps in an example method for forming an EMI shielded semiconductor package. FIG. 1A shows in-process results after forming a first layer 115 on a carrier 105 (such as a metal carrier) comprising a first metal layer shown including a first metal trace 115 a that is embedded in a first dielectric layer 115 b that can comprise a mold compound. The first metal trace 115 a upon a conclusion of the method provides what will be a top EMI shield for an IC below. Although the first metal trace 115 a is shown as a continuous structure that covers an entire area of the IC die 120, the first metal trace 115 a can also be a patterned structure that includes gaps so that it does not covers all of the area of the IC die.

FIG. 1B shows in-process results after attaching an IC die 120 including circuitry 180 connected to bond pads 121 with its top side up using a die attach material 124 to attach the bottom side of the IC die 120. The die attach material 124 can comprise a dielectric material or can comprise an electrically and thermally conductive material, such as an epoxy with silver particles or solder.

For example, in the case of a dielectric die attach material, the die attach material 124 can comprise a die attach film (DAF) on the first metal trace 115 a. The circuitry 180 for the IC die comprises circuit elements (including transistors, and generally diodes, resistors, capacitors, etc.) that may be formed in the epitaxial layer on a bulk substrate material, where the circuitry 180 is configured together for generally realizing at least one circuit function. Example circuit functions include analog (e.g., amplifier or power converter), radio frequency (RF), digital, or non-volatile memory functions.

FIG. 1C shows in-process results after forming metal pillars 132 on the first metal trace 115 a positioned lateral to the IC die 120. The metal pillars 132 generally comprise copper, and have a height that extends above the top side surface of the IC die 120. A plating process can be used for forming the metal pillars 132. The metal pillars 132 can in one arrangement have a rectangular prism shape, which is defined as a 3-dimensional solid shape which has six faces that are all rectangles. In addition, the metal pillars 132 can generally have a variety of other shapes such as cylindrical, where the shape of the metal pillars 132 that can generally be designed depending on a given application.

Although a plurality of spaced apart metal pillars 132 are generally formed, such as depicted in FIG. 1C and FIG. 2 described below, it may also be possible for instead of a plurality of spaced apart metal pillars 132, a continuous (single) metal ring can be formed around the IC die 120. In the case of spaced apart metal pillars 132, a nominal spacing can be 0.5 mm±20%. Again, in the case spaced apart metal pillars 132, the metal pillars 132 can collectively cover 10% to 40% of the area around the IC die 120. Regarding the gap between the adjacent metal pillars 132, the gap is generally a minimum of 0.1 mm, and a maximum which can depend on the IC die size. An area for the metal pillars 132 can be 0.05 mm² and 2 mm².

FIG. 1D shows in-process results after forming a second dielectric layer 116 b, such as using a molding process to form a mold compound, and then grinding to expose a top surface of the metal pillars 132. FIG. 1E shows in-process results after forming vias 116 c through the second dielectric layer 116 b, such as using laser drilling, where the vias 116 c are positioned over the bond pads 121. The vias 116 c reach a top surface of the bond pads 121 to enable making a contact to the bond pads 121 as described below.

FIG. 1F shows in-process results after forming a third layer 117 on the second layer including a second metal layer 117 a including a plurality of second metal traces comprising outer metal traces 117 a 1 that each connect to a metal pillar 132, and inner metal traces 117 a 2 that included vertical section that fills the vias 116 c shown in FIG. 1E to form filled vias 117 v that connect to the bond pads 121. The third layer 117 also includes a third dielectric layer 117 b, such as comprising a mold layer, and filled vias 117 c that. provide externally accessible contact pads that connect the second metal traces to a bottom side of the semiconductor package shown at the top of FIG. 1F, that has second filled vias 117 c embedded therein that contact the inner metal traces 117 a 2 and the outer metal traces 117 a 1.

Although not shown, the method can further comprise forming a fourth layer on the third layer 117. In one arrangement fourth layer is essentially identical to the third layer, and the metal traces of the fourth layer are aligned to the outer metal traces 117 a 1 in the inner metal traces 117 a 2. Advantages to forming this fourth layer can be better thermal performance and PCB level reliability, where is the fourth layer used for the connection to the PCB.

FIG. 1G shows in-process results after removing the carrier 105 and flipping the in-process package substrate, and then singulation generally comprising a sawing process in the typical case of a panel of EMI shielded semiconductor packages to provide a plurality of singulated EMI shielded semiconductor packages shown as an EMI shielded semiconductor package 190. After removing the carrier 105, there may be a surface finish treatment before the singulation. A total thickness of the EMI shielded semiconductor package 190 may be 350 μm to 600 μm, such as about 450 μm. The metal pillars 132 may have a height that is between 50% and 90% of the total thickness of the EMI shielded semiconductor package 190.

FIG. 2 is a top view 200 corresponding to the structure shown in FIG. 1C which as described above shows in-process results after forming metal pillars 132 on the first metal trace 115 a lateral to the IC die 120, according to an example aspect. There can be seen to be gaps 133 between neighboring metal pillars 132. Although shown having a rectangular cross-section, the metal pillars 132 as described above can also have other shapes including a circular cross-section or other elliptical cross-section.

FIG. 3A and FIG. 3B show a top perspective view and a cross-sectional view, respectively, of a semiconductor package assembly 300 comprising a disclosed EMI shielded semiconductor package comprising an IC die 120 (such as the EMI shielded semiconductor package 190 shown in FIG. 1G described above) embedded within a package substrate mounted on pads 321 on a top surface of a PCB 320 that provides a bottom metal shield 371 for the IC die 120 that is shown covering an entire area of the IC die 120. There is a top metal EMI shield shown as 315 a above the IC 120, which corresponds to first metal trace 115 a described above. Metal traces on the PCB 320 are shown as 322. In FIG. 3B, the PCB 320 is also shown with its dielectric layer 326 having embedded filled vias 327 connected to metal pads 328.

Examples

Disclosed aspects are further illustrated by the following specific Examples, which should not be construed as limiting the scope or content of this Disclosure in any way.

An EMI simulation was run to compare results from a conventional fused Thin Shrink Small Outline Package (TSSOP) versus a disclosed EMI shielded device. The TSSOP is a rectangular surface mount plastic IC package with gull-wing leads. The electric field data evidenced that a disclosed package substrate including EMI shielding reduces an electric field by a factor of three (from 30 V/m to 10 V/m) received on the top surface of the IC die as compared to a conventional fused TSSOP.

Disclosed aspects can be integrated into a variety of assembly flows to form a variety of different semiconductor packages and related products. The semiconductor package can comprise single IC die or multiple IC die, such as configurations comprising a plurality of stacked IC die, or laterally positioned IC die. A variety of package substrates may be used. The IC die may include various elements therein and/or layers thereon, including barrier layers, dielectric layers, device structures, active elements and passive elements including source regions, drain regions, bit lines, bases, emitters, collectors, conductive lines, conductive vias, etc. Moreover, the IC die can be formed from a variety of processes including bipolar, insulated-gate bipolar transistor (IGBT), CMOS, BiCMOS and MEMS.

Those skilled in the art to which this Disclosure relates will appreciate that many variations of disclosed aspects are possible within the scope of the claimed invention, and further additions, deletions, substitutions and modifications may be made to the above-described aspects without departing from the scope of this Disclosure. 

The invention claimed is:
 1. A semiconductor package, comprising: a multilayer package substrate comprising a first layer including a first dielectric layer and a first metal layer including at least a first metal trace and a second layer including a second dielectric layer; an integrated circuit (IC) die comprising a substrate having a semiconductor surface including circuitry, with nodes of the circuitry connected to bond pads, a bottom side of the IC die attached to the first metal trace by a die attach material, wherein at least one edge of the first metal trace extends beyond a corresponding edge of the IC die; metal pillars through the second dielectric layer connecting to the first metal trace; and a third layer on the second layer including a third dielectric layer extending toward a bottom side of the semiconductor package, and a second metal layer including a plurality of second metal traces comprising inner second metal traces connected to the bond pads and outer second metal traces over the metal pillars, and filled vias providing externally accessible contact pads that connect the second metal traces to the bottom side of the semiconductor package.
 2. The semiconductor package of claim 1, wherein the first metal trace covers all of an area of the IC die.
 3. The semiconductor package of claim 1, wherein the first metal trace is a patterned structure that includes gaps so that it does not covers all of an area of the IC die.
 4. The semiconductor package of claim 1, wherein the inner second metal traces collectively cover at least 50% of an area of the IC die.
 5. The semiconductor package of claim 1, wherein the IC die comprises a power metal oxide semiconductor field effect transistor (MOSFET), a controller with a gate driver, an analog-to-digital converter (ADC), digital circuitry, control and compensation circuitry, or a digital-to-analog converter (DAC).
 6. The semiconductor package of claim 1, wherein the IC die comprises an audio amplifier.
 7. The semiconductor package of claim 1, wherein the metal pillars have a height that is 50% to 90% of a thickness of the semiconductor package.
 8. The semiconductor package of claim 1, wherein an area of the metal pillars is between 0.05 mm² and 2 mm².
 9. The semiconductor package of claim 1, wherein the metal pillars comprise a plurality of spaced apart ones of the metal pillars.
 10. A semiconductor package assembly, comprising: a semiconductor package, comprising: a multilayer package substrate comprising a first layer including a first dielectric layer and a first metal layer including at least a first metal trace and a second layer including a second dielectric layer; an integrated circuit (IC) die comprising a substrate having a semiconductor surface including circuitry, with nodes of the circuitry connected to bond pads, a bottom side of the IC die attached to the first metal trace by a die attach material, wherein at least one edge of the first metal trace extends beyond a corresponding edge of the IC die; metal pillars through the second dielectric layer connecting to the first metal trace; and a third layer on the second layer including a third dielectric layer extending toward a bottom side of the semiconductor package, and a second metal layer including a plurality of second metal traces comprising inner second metal traces connected to the bond pads and outer second metal traces over the metal pillars, and filled vias providing externally accessible contact pads that connect the second metal traces to the bottom side of the semiconductor package; and a printed circuit board (PCB), wherein the semiconductor package is bonded onto a top surface of the PCB, and wherein the top surface of the PCB provides a bottom metal electromagnetic interference (EMI) shield for the semiconductor package assembly.
 11. The semiconductor package assembly of claim 10, wherein the first metal trace covers an entire area of the IC die.
 12. The semiconductor package assembly of claim 10, wherein the first metal trace is a patterned structure that includes gaps so that it does not covers all of an area of the IC die.
 13. The semiconductor package assembly of claim 10, wherein the IC die comprises a power metal oxide semiconductor field effect transistor (MOSFET), a controller with a gate driver, an analog-to-digital converter (ADC), digital circuitry, control and compensation circuitry, a digital-to-analog converter (DAC), or an audio amplifier.
 14. The semiconductor package assembly of claim 10, wherein the metal pillars comprise a plurality of spaced apart ones of the metal pillars.
 15. The semiconductor package assembly of claim 10, wherein the inner second metal traces collectively cover at least 50% of an area of the IC die.
 16. A method of assembling a semiconductor package, comprising: forming a first layer on a carrier, the first layer including a first dielectric layer and a first metal layer including at least a first metal trace; attaching an integrated circuit (IC) die comprising a substrate having a semiconductor surface including circuitry, with a bottom side of the IC die attached to the first metal trace by a die attach material, wherein at least one edge of the first metal trace extends beyond a corresponding edge of the IC die; forming metal pillars on the first metal trace beyond an area of the IC die; forming a second dielectric layer having a thickness that extends to a top side of the metal pillars; forming vias in the second dielectric layer that reach bond pads of the IC die; forming a third dielectric layer extending toward a bottom side of the semiconductor package; forming a second metal layer including a plurality of second metal traces comprising inner second metal traces connected to the bond pads and outer second metal traces over the metal pillars; and forming filled vias through the third dielectric layer providing externally accessible contact pads that connect the second metal traces to the bottom side of the semiconductor package.
 17. The method of claim 16, wherein the first metal trace covers all of the area of the IC die.
 18. The method of claim 16, wherein the metal pillars comprise a plurality of spaced apart ones of the metal pillars.
 19. The method of claim 16, wherein the inner second metal traces collectively cover at least 50% of the area of the IC die.
 20. The method of claim 16, wherein the die attach material comprises a thermally conductive material, and wherein the IC die comprises a power metal oxide semiconductor field effect transistor (MOSFET), a controller with a gate driver, an analog-to-digital converter (ADC), digital circuitry, control and compensation circuitry, a digital-to-analog converter (DAC), or an audio amplifier.
 21. The method of claim 16, wherein the metal pillars have a height that is 50% to 90% of a thickness of the semiconductor package. 